CN105033763A - Method for predicting abrasion state of numerically-controlled machine tool ball screw - Google Patents
Method for predicting abrasion state of numerically-controlled machine tool ball screw Download PDFInfo
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- CN105033763A CN105033763A CN201510559313.5A CN201510559313A CN105033763A CN 105033763 A CN105033763 A CN 105033763A CN 201510559313 A CN201510559313 A CN 201510559313A CN 105033763 A CN105033763 A CN 105033763A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/007—Arrangements for observing, indicating or measuring on machine tools for managing machine functions not concerning the tool
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Abstract
The invention discloses a method for predicting abrasion state of a numerically-controlled machine tool ball screw. The method comprises the following steps that three-phase current signals of a motor of a feed shaft of a numerically-controlled machine tool are collected and preprocessed, and then the root-mean-square value IRMS of the three-phase current is calculated; frequency-domain analysis is performed on the root-mean-square value IRMS so as to obtain current signal frequency-domain energy distributions formed before and after the ball screw of the feed shaft is abraded, and the frequency corresponding to current signal mutation is obtained according to the comparison of the current signal frequency-domain energy distributions formed before and after the ball screw of the feed shaft is abraded; and according to the obtained frequency, a wavelet packet is selected for decomposing the layer number,, wavelet packet decomposition is performed on the root-mean-square value IRMS to obtain multiple wavelet packet components, the variance characteristic value of a signal obtained after wavelet packet components on the sensitive segment are reconstructed is calculated, and the abrasion state of the numerically-controlled machine tool ball screw is predicted based on the variance characteristic value. The method has the beneficial effects of being high in prediction speed, low in cost and high in accuracy rate, and the abrasion state of the ball screw can be rapidly evaluated.
Description
Technical field
The invention belongs to ball-screw state of wear prediction field, more specifically, relate to a kind of Forecasting Methodology of Ball-screw in NC Machine Tools state of wear.
Background technology
The projected life of ball-screw is 1-1.5 ten thousand hours, along with Digit Control Machine Tool processing towards at a high speed, highly to accelerate, high-precision, heavy duty development, often do not reach projected life ball-screw and just occurred damage.The damage type that ball-screw the most easily occurs is wearing and tearing, predicts, to occur that to ball-screw state of wear obtains the index of a Relative quantification to Machine Tool Feeding System ball-screw state of wear, can take measures in time, ensure work pieces process quality, rate of reducing the number of rejects and seconds, improve working (machining) efficiency.
Current machine tool wear monitoring method is mainly divided into direct monitoring method and indirect monitoring method.Direct monitoring method directly measures its wear extent, although direct monitoring method can measure the wear extent of wearing terrain more accurately, it measures inconvenience, and some parts is as ball-screw, bearing, guide rail, the unspecial instrument measuring wearing and tearing, not easily obtains wear extent accurately.Indirect monitoring method is by obtaining lathe signal, by realizing the wear condition monitoring of machine tool component to signal analysis, monitor signal is obtained by different sensors, sensor can obtain than more rich transducing signal, RyutaSATO as Kobe University utilizes the wear measuring method that motor current signal assists speed, position signals establishes ball screw assembly, by contrasting with the backlass of actual measurement, demonstrate the validity of the method, but author thinks that backlass is the wear extent of ball-screw; The and for example Huanghai Sea phoenix of Southwest Jiaotong University in 2013, by gathering current signal, the vibration signal of the motor be connected with ball-screw, the performance degradation of ball-screw is monitored, but it mainly constructs by building the change of current signal, vibration signal and coefficient of friction the monitoring method that leading screw weares and teares.
But further studying, still there is following defect or deficiency in above-mentioned prior art: although said method exists certain feasibility, it is very inconvenient in engineer applied, and testing cost is higher; Although the acquisition of current signal is relatively simple, does not mention in said method, do not relate to the Fast Identification under machine tooling state first, second do not evoke the trend leading screw state of wear of energy from lathe electric current signal combination lathe.
Summary of the invention
For above defect or the Improvement requirement of prior art, the invention provides a kind of Forecasting Methodology of Ball-screw in NC Machine Tools state of wear, it is by obtaining machine tool feed spindle motor current signal, through WAVELET PACKET DECOMPOSITION after pretreatment, extract corresponding frequency band Variance feature value, realize the prediction to ball-screw state of wear, it adopts current signal as monitor signal, there is signal acquisition easy, sensor cost is low, the feature such as easy for installation, WAVELET PACKET DECOMPOSITION can by signal decomposition to different frequency ranges simultaneously, the characteristic value extracted from the frequency range at change frequency place, ball-screw wearing and tearing front and back is more stable, can effecting reaction ball-screw state of wear, there is the advantages such as computational speed is fast, thus the on-line prediction of Ball-screw in NC Machine Tools state of wear is particularly useful for.
For achieving the above object, the present invention proposes a kind of Forecasting Methodology of Ball-screw in NC Machine Tools state of wear, it is characterized in that, comprise the steps:
(1) gather the three-phase current signal of Digit Control Machine Tool feed shaft motor to be measured, pretreatment is carried out to described three-phase current signal, then calculate the root-mean-square value I obtaining three-phase current
rMS;
(2) to described root-mean-square value I
rMScarry out frequency-domain analysis, obtain the current signal frequency domain energy distribution of the ball-screw wearing and tearing front and back of described feed shaft, according to the contrast that the current signal frequency domain energy distribution after described ball-screw wearing and tearing and the current signal frequency domain energy before its wearing and tearing distribute, obtain frequency corresponding when current signal suddenlys change;
(3) according to the He Ne laser WAVELET PACKET DECOMPOSITION number of plies obtained in step (2), then according to this WAVELET PACKET DECOMPOSITION number of plies to described root-mean-square value I
rMScarry out WAVELET PACKET DECOMPOSITION, by described root-mean-square value I
rMStime-domain signal decompose different frequency ranges, obtain multiple wavelet packet component thus, signal reconstruction is carried out to the wavelet packet component comprising described frequency, obtain the Variance feature value of the wavelet packet component after this signal reconstruction, realize the prediction of Ball-screw in NC Machine Tools state of wear with this variance characteristic value.
As preferred further, described pretreatment, for carry out LPF to described three-phase current signal, with filtering noise, improves signal to noise ratio.
As preferred further, the root-mean-square value of described three-phase current
wherein i
u, i
v, i
wfor the three-phase alternating current of motor.
As preferred further, the described WAVELET PACKET DECOMPOSITION number of plies is preferably 5 layers.
As preferred further, the progressively increasing of wearing and tearing along with described ball-screw, the Variance feature value of acquisition progressively increases, and when described ball-screw reaches the terminal in life-span completely, described Variance feature value is 0.2.
As preferred further, when after the ball-screw more renewed, described Variance feature value can obviously reduce, and levels off to 0.
In general, the above technical scheme conceived by the present invention compared with prior art, mainly possesses following technological merit: the present invention adopts current signal as monitor signal, there is signal acquisition easy, antijamming capability is strong, the features such as sensor cost is low, easy for installation, there is good universality in engineering practice, therefore have great advantage in actual applications; The present invention adopts WAVELET PACKET DECOMPOSITION by signal decomposition to different frequency ranges, to be more conducive to extracting the information relevant to ball-screw state of wear; The present invention extracts characteristic value from the frequency range at change frequency place, ball-screw wearing and tearing front and back, and characteristic value based on comprise frequency wavelet packet component reconstruct after signal ask its Variance feature value, effectively can reflect the state of wear that ball-screw weares and teares, there is computational speed fast, recognition accuracy is high, predicts more stable advantage.
Accompanying drawing explanation
Fig. 1 is the Forecasting Methodology schematic flow sheet that the embodiment of the present invention provides;
Fig. 2 is current signal monitoring system schematic diagram of the present invention;
Fig. 3 is the current signal spectrogram of the process that the present invention collects;
Fig. 4 (a) and Fig. 4 (b) is current signal frequency domain energy profiles versus figure before and after ball-screw of the present invention wearing and tearing respectively;
Fig. 5 is WAVELET PACKET DECOMPOSITION schematic diagram of the present invention;
Fig. 6 is current signal characteristics extraction process schematic of the present invention;
Fig. 7 is the current signal characteristic value that the present invention extracts;
Fig. 8 is the Variance feature value that different lathe extracts.
Detailed description of the invention
In order to make object of the present invention, technical scheme and advantage clearly understand, below in conjunction with drawings and Examples, the present invention is further elaborated.Should be appreciated that specific embodiment described herein only in order to explain the present invention, be not intended to limit the present invention.In addition, if below in described each embodiment of the present invention involved technical characteristic do not form conflict each other and just can mutually combine.
Ball-screw state of wear Forecasting Methodology provided by the invention, by obtaining the current signal of machine tool feed spindle motor, through WAVELET PACKET DECOMPOSITION and characteristics extraction process after pretreatment, set up ball-screw state of wear identification model, by long monitoring, be reached through the object of current signal prediction ball-screw state of wear.
Object of the present invention is for the XS211 horizontal Machining centers produced in MAG company of the U.S., choose its certain manufacturing procedure of producing in cylinder cap to analyze, identification is carried out to the state of wear of its X-axis leading screw, the current signal that invention has been in long process obtains, and predicts ball-screw state of wear.As shown in Figure 1, the embodiment of the present invention specifically comprises the following steps:
(1) gather the three-phase current signal of Digit Control Machine Tool feed shaft motor to be measured, pretreatment is carried out to described three-phase current signal, then calculate the root-mean-square value I obtaining three-phase current
rMS.
Concrete, as shown in Figure 2, utilize Hall element to gather the three-phase current of Digit Control Machine Tool feed shaft motor, and LPF is carried out to current signal, filtering noise, improve signal to noise ratio.The electric current that motor exports is respectively motor three-phase alternating current i
u, i
v, i
w, I
rMSfor the root-mean-square value of three-phase current
transmission duty containing Machine Tool Feeding System leading screw in its current signal, the current signal I collected
rMSvalue as shown in Figure 3.
(2) to the current signal root-mean-square value I in process
rMScarry out Fast Fourier Transform (FFT), analyze its frequency domain energy distribution situation, obtain the frequency spectrum under ball-screw different conditions, current signal frequency domain energy changes in distribution before and after the wearing and tearing of contrast ball-screw, according to the contrast that the current signal frequency domain energy distribution after described ball-screw wearing and tearing and the current signal frequency domain energy before its wearing and tearing distribute, select its frequency energy and change the foundation of larger frequency (namely corresponding during current signal sudden change frequency) as the selection of the WAVELET PACKET DECOMPOSITION number of plies, can reflect because ball-screw weares and teares the most responsive frequency content of the frequency domain energy changes in distribution that causes by carrying out frequency-domain analysis to the current signal before and after ball-screw wearing and tearing.
Concrete, as shown in Figure 4, two kinds of signals in Fig. 4 are the spectrum analysis of the signal that leading screw gathers under end of life and new leading screw two kinds of conditions respectively, can find that its current signal change when 32.23hz is the most responsive by contrast, relatively very greatly, its epidemic situation comparison characterizing leading screw in whole process is responsive, the lower step WAVELET PACKET DECOMPOSITION number of plies can be it can be used as thus to choose and provide foundation for the change of its frequency energy, when carrying out wavelet packet analysis, its frequency band comprises this frequency content.
(3), after analyzing according to step (2) intermediate frequency spectrum, the root-mean-square value of determination to each current signal obtained of responsive frequency range carries out the decomposition of multi-level Wavelet Transform bag, by I
rMScarry out Wavelet Packet Theory and decompose different frequency ranges, obtain multiple wavelet packet component, according to frequency domain energy difference in distribution before and after ball-screw wearing and tearing, signal after the wavelet packet component comprising sensitive frequency reconstructs asks its Variance feature value, realizes the prediction of Ball-screw in NC Machine Tools state of wear with this variance characteristic value.Because ball-screw wearing and tearing can cause frequency domain energy to change, current signal in whole frequency domain can be decomposed different frequency ranges by WAVELET PACKET DECOMPOSITION, the frequency extraction characteristic value at change frequency place before and after ball-screw wearing and tearing, the characteristic value that sign ball-screw can be made to wear and tear is more stable, more can reflect the state of wear of ball-screw.
Concrete, according to most sensitive frequency determination Decomposition order, wherein the sample frequency of current signal is 2000HZ, the effective frequency of WAVELET PACKET DECOMPOSITION is 1000HZ, the most responsive frequency content is 32.23hz, carries out 5 layers of decomposition to wavelet packet, and each frequency range of the 5th layer is 1000/25=31.25HZ, wavelet packet component (5, 1) frequency range comprised is 31.25hz ~ 62.5hz, just in time contains the most responsive frequency content 32.23hz, when analyzing current signal, the WAVELET PACKET DECOMPOSITION number of plies is more, more can be positioned with by frequency, but Decomposition order too much can cause frequency alias, directly selects wavelet packet 5 layers to decompose through actual analysis, the decomposing schematic representation of wavelet packet as shown in Figure 5, according to Fig. 5, initiation layer is (0,0), ground floor is (1,0), (1,1), the second layer is (2,0), (2,1), (2,2), (2,3), third layer is (3,0), (3,1), (3,2), (3,3), (3,4), (3,5), (3,6), (3,7), the 4th layer has 16 wavelet packet components, is (4,0), (4,1), (4,2), (4,13), (4,14), (4,15), layer 5 has 32 wavelet packet components, is respectively (5,0), (5,1), (5,2), (5,29), (5,30), (5,31).
Then to the wavelet packet component (5 forgiving sensitive frequency, 1) be reconstructed, be designated as yat (2), ask its Variance feature value va, va=var (yat (2)), wherein yat (2) represents the signal after wavelet packet component (5,1) reconstruct, and var representative solves the function of variance.The present embodiment chooses the relative energy of responsive frequency range after the current signal wavelet packet analysis in the milling face process of each processing work as analyzing samples, variance analysis is carried out to it, through continuous continuously signals collecting, extract the process of characteristic value as shown in Figure 6, the current signal Variance feature value extracted as shown with 7, a point representation feature value linear trend in Fig. 7, current signal Variance feature value when b point is for changing old leading screw, current signal Variance feature value when c point is for changing new leading screw.
Finally by the evaluation index of the Variance feature value of extraction as evaluation leading screw state, realize the prediction of ball-screw state of wear, its Appreciation gist is as follows: along with the wearing and tearing deterioration of leading screw is more and more serious, the Variance feature value extracted presents the trend of increase, along with the progressively increasing of leading screw wearing and tearing, its Variance feature value obtained progressively increases, when leading screw reaches the terminal in life-span completely, Variance feature value reaches 0.2, simultaneously after the leading screw more renewed, its characteristic value can significantly reduce, level off to 0, therefore the signal after current signal wavelet packet component can be adopted to reconstruct asks its Variance feature value as the evaluation index evaluating leading screw state, duty for leading screw passes through its current signal of timing acquisition, it is carried out to the extraction of Variance feature value, then can the duty of its leading screw of Quick.Be illustrated in figure 8 different lathe and extract its Variance feature value, Variance feature value corresponding when wherein a and c is moderate wearing and tearing, the Variance feature value that b is corresponding when being heavy wear, the Variance feature value that d is corresponding when being mild wear, the different state of wear of leading screw are symbolized with Variance feature value, the Variance feature value of this complete leading screw can be assessed as the duty of leading screw of the same type, be that accurate assessment is made to the real-time status of leading screw first, the effective time of leading screw can be gone out simultaneously by the comparison prediction of sample characteristics.
To sum up, the present invention is by obtaining machine tool feed spindle motor current signal, extract through WAVELET PACKET DECOMPOSITION and corresponding frequency band Variance feature value after pretreatment, realize the prediction to ball-screw state of wear, be reached through the object of current signal prediction ball-screw state of wear, there is the advantage that predetermined speed is fast, cost is low, accuracy rate is high, the on-line r apid estimation of ball-screw state of wear can be realized.
Those skilled in the art will readily understand; the foregoing is only preferred embodiment of the present invention; not in order to limit the present invention, all any amendments done within the spirit and principles in the present invention, equivalent replacement and improvement etc., all should be included within protection scope of the present invention.
Claims (6)
1. a Forecasting Methodology for Ball-screw in NC Machine Tools state of wear, is characterized in that, comprises the steps:
(1) gather the three-phase current signal of Digit Control Machine Tool feed shaft motor to be measured, pretreatment is carried out to described three-phase current signal, then calculate the root-mean-square value I obtaining three-phase current
rMS;
(2) to described root-mean-square value I
rMScarry out frequency-domain analysis, obtain the current signal frequency domain energy distribution of the ball-screw wearing and tearing front and back of described feed shaft, according to the contrast that the current signal frequency domain energy distribution after described ball-screw wearing and tearing and the current signal frequency domain energy before its wearing and tearing distribute, obtain frequency corresponding when current signal suddenlys change;
(3) according to the He Ne laser WAVELET PACKET DECOMPOSITION number of plies obtained in step (2), then according to this WAVELET PACKET DECOMPOSITION number of plies to described root-mean-square value I
rMScarry out WAVELET PACKET DECOMPOSITION, by described root-mean-square value I
rMStime-domain signal decompose different frequency ranges, obtain multiple wavelet packet component thus, signal reconstruction is carried out to the wavelet packet component comprising described frequency, obtain the Variance feature value of the wavelet packet component after this signal reconstruction, realize the prediction of Ball-screw in NC Machine Tools state of wear with this variance characteristic value.
2. the Forecasting Methodology of Ball-screw in NC Machine Tools state of wear as claimed in claim 1, is characterized in that, described pretreatment, for carry out LPF to described three-phase current signal, with filtering noise, improves signal to noise ratio.
3. the Forecasting Methodology of Ball-screw in NC Machine Tools state of wear as claimed in claim 1 or 2, is characterized in that, the root-mean-square value of described three-phase current
wherein i
u, i
v, i
wfor the three-phase alternating current of motor.
4. the Forecasting Methodology of Ball-screw in NC Machine Tools state of wear as claimed in claim 3, it is characterized in that, the described WAVELET PACKET DECOMPOSITION number of plies is preferably 5 layers.
5. the Forecasting Methodology of Ball-screw in NC Machine Tools state of wear as claimed in claim 4, it is characterized in that, the progressively increasing of wearing and tearing along with described ball-screw, the Variance feature value of acquisition progressively increases, when described ball-screw reaches the terminal in life-span completely, described Variance feature value is 0.2.
6. the Forecasting Methodology of Ball-screw in NC Machine Tools state of wear as claimed in claim 5, is characterized in that, when after the ball-screw more renewed, described Variance feature value can obviously reduce, and levels off to 0.
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| CN108255131A (en) * | 2016-12-28 | 2018-07-06 | 发那科株式会社 | The method in the service life of lathe, production management system and prediction and/or detection instrument |
| TWI629136B (en) * | 2017-07-31 | 2018-07-11 | 鍵和機械股份有限公司 | Method of touch detection |
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| CN111623867A (en) * | 2020-04-27 | 2020-09-04 | 中国人民解放军海军士官学校 | Method for predicting wear state of cylinder sleeve-piston assembly |
| CN112476056A (en) * | 2020-11-13 | 2021-03-12 | 宁波天控五轴数控技术有限公司 | Machine tool impact recognition system |
| CN114545228A (en) * | 2022-01-26 | 2022-05-27 | 图湃(北京)医疗科技有限公司 | OCT system ball screw wear state monitoring method based on motor current feedback |
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| CN107877262A (en) * | 2017-11-13 | 2018-04-06 | 华中科技大学 | A kind of numerical control machine tool wear monitoring method based on deep learning |
| CN109773584A (en) * | 2017-11-15 | 2019-05-21 | 大隈株式会社 | The operating status display device and running-state displaying method of the feed shaft of lathe |
| CN109773584B (en) * | 2017-11-15 | 2022-04-22 | 大隈株式会社 | Running state display device and running state display method for feed shaft of machine tool |
| CN108536095A (en) * | 2018-04-24 | 2018-09-14 | 湖北文理学院 | A kind of leading screw wear extent real-time predicting method |
| CN111623867A (en) * | 2020-04-27 | 2020-09-04 | 中国人民解放军海军士官学校 | Method for predicting wear state of cylinder sleeve-piston assembly |
| CN112476056A (en) * | 2020-11-13 | 2021-03-12 | 宁波天控五轴数控技术有限公司 | Machine tool impact recognition system |
| CN114545228A (en) * | 2022-01-26 | 2022-05-27 | 图湃(北京)医疗科技有限公司 | OCT system ball screw wear state monitoring method based on motor current feedback |
| CN114545228B (en) * | 2022-01-26 | 2022-11-22 | 图湃(北京)医疗科技有限公司 | OCT system ball screw wear state monitoring method based on motor current feedback |
| CN117697353A (en) * | 2024-02-05 | 2024-03-15 | 东莞市扬牧数控科技有限公司 | Intelligent fault diagnosis method for numerical control machine tool |
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